Design And Apply Modifications To Existing Process Control Systems Training

Objectives:
• Understand the role of process control systems in industrial environments.
• Identify key components and their functions in a control loop.
• Define modifications and their impact on system performance.
• Recognise relevant safety and regulatory standards.
• Explain the purpose of Unit Standard 119809.

Topics:
• Overview of process control systems (e.g., SCADA, DCS, PLC).
• Basic control loop components: sensors, controllers, actuators.
• Types of modifications: hardware, software, parameter changes.
• Safety and regulatory considerations (e.g., OHS Act, SANS).
• Introduction to the unit standard: outcomes and assessment criteria.
• Case study: simple modification example (e.g., changing setpoint).

Objectives:
• Describe measurement principles for common process variables.
• Select appropriate instruments for given applications.
• Interpret instrument specifications and datasheets.
• Understand calibration and its importance in modifications.

Topics:
• Measurement of temperature, pressure, flow, level, and pH.
• Sensor types: thermocouples, RTDs, pressure transmitters, flowmeters.
• Instrument selection criteria: range, accuracy, environment.
• Calibration procedures and traceability.
• Impact of instrument accuracy on control system modifications.

Objectives:
• Identify and describe the function of controllers, final control elements, and signal conditioning.
• Configure basic controller parameters (P, I, D).
• Explain signal types (analog, digital) and their conversion.
• Understand wiring and termination practices.

Topics:
• Controllers: PLC, DCS, PID controllers.
• Final control elements: valves, actuators, variable speed drives.
• Signal conditioning: 4-20 mA, 0-10 V, digital signals.
• Basic PID tuning: proportional, integral, derivative actions.
• Wiring diagrams and termination panels.
• Hands-on: configuring a simple PID loop in simulation.

Objectives:
• Interpret P&IDs and loop diagrams.
• Create modification requests and change control documentation.
• Follow management of change (MOC) procedures.
• Understand the importance of version control and traceability.

Topics:
• P&ID symbols and loop diagrams.
• Modification request forms: scope, justification, risk assessment.
• Management of change (MOC) process steps.
• Document control: revision history, approval workflows.
• Case study: reviewing a modification request.
• Exercise: updating a loop diagram after a sensor change.

Objectives:
• Conduct a risk assessment for proposed modifications.
• Apply hierarchy of controls to mitigate risks.
• Understand functional safety concepts (SIL).
• Identify permit-to-work requirements.

Topics:
• Hazard identification techniques (e.g., HAZOP, what-if).
• Risk matrix: likelihood and severity.
• Hierarchy of controls: elimination, substitution, engineering, administrative, PPE.
• Introduction to functional safety and Safety Integrity Levels (SIL).
• Permit-to-work systems for modification activities.
• Practical: risk assessment for a valve replacement.

Objectives:
• Develop a detailed modification plan.
• Identify required resources, tools, and spares.
• Create a step-by-step implementation procedure.
• Coordinate with stakeholders and schedule shutdowns.

Topics:
• Modification plan components: scope, timeline, resources.
• Resource identification: personnel, equipment, software.
• Step-by-step procedure development.
• Shutdown planning and isolation procedures.
• Communication with operations, maintenance, and engineering.
• Exercise: writing a procedure for a controller upgrade.

Objectives:
• Perform hardware modifications such as sensor or actuator replacement.
• Follow safe isolation and reconnection procedures.
• Verify physical installation against specifications.
• Document as-built changes.

Topics:
• Isolation procedures: lockout/tagout (LOTO).
• Sensor replacement: removal, installation, alignment.
• Actuator replacement: valve, motor, drive.
• Cable routing and termination checks.
• As-built documentation updates.
• Practical: replacing a pressure transmitter in a training rig.

Objectives:
• Modify controller parameters and logic.
• Upload/download programs safely.
• Verify software changes against design.
• Understand version control for software.

Topics:
• Changing PID parameters, setpoints, alarm limits.
• Modifying PLC logic (e.g., adding a timer).
• Safe program upload/download procedures.
• Software version control and backup.
• Testing software changes in simulation.
• Practical: adjusting PID settings in a virtual plant.

Objectives:
• Develop a commissioning test plan.
• Perform loop checks and functional tests.
• Tune controllers after modifications.
• Document test results and deviations.

Topics:
• Commissioning test plan: test cases, acceptance criteria.
• Loop checks: signal continuity, response time.
• Functional testing: open/close, ramp, step tests.
• Controller tuning after modification: Ziegler-Nichols, trial and error.
• Deviation handling and rework procedures.
• Practical: commissioning a modified flow control loop.

Objectives:
• Identify common issues arising from modifications.
• Use systematic troubleshooting methods.
• Diagnose hardware and software faults.
• Implement corrective actions effectively.

Topics:
• Common modification issues: wiring errors, parameter mismatch, noise.
• Troubleshooting methodology: observe, isolate, test, resolve.
• Diagnostic tools: multimeter, oscilloscope, software diagnostics.
• Fault-finding in PLC and DCS systems.
• Case studies: troubleshooting a failed modification.
• Practical: diagnosing a simulated fault after a sensor change.

Objectives:
• Complete all modification documentation.
• Prepare handover documentation for operations.
• Conduct operator training on modified systems.
• Ensure ongoing support and maintenance plans.

Topics:
• Final documentation: as-built drawings, test reports, MOC closure.
• Handover package: operating instructions, alarm settings, maintenance tips.
• Operator training: new features, changes in operation, safety.
• Maintenance plan updates: spares, calibration schedules.
• Exercise: creating a handover document for a modification.
• Simulated handover presentation.

Objectives:
• Review the entire modification process.
• Participate in a post-implementation review.
• Identify lessons learned and improvement opportunities.
• Complete unit standard assessments.

Topics:
• Post-implementation review: performance, cost, safety.
• Lessons learned log and continuous improvement.
• Summary of unit standard outcomes.
• Practical assessment: plan and execute a simple modification.
• Written assessment: knowledge questions.
• Course evaluation and feedback.